Vertical support and single-wrap collapsible container

ABSTRACT

A container comprising a collapsible continuous rigid structure defining a plurality of outer surfaces and a plurality of inner surfaces that can be used for storing and/or transporting materials. A liner uniformly affixed to at least one inner surface, such that the liner defines a sealable cavity within which material can be contained. At least one stay member is affixed to at least one outer surface such that at least a portion of the at least one stay member is positioned approximate a corner formed by two adjacent outer surfaces so as to provide support to the rigid structure. A continuous or single cover is affixed to at least one outer surface and to the at least one stay member. Further, at least one inelastic member is connecting the plurality of inner and/or outer surfaces so as to provide support for the continuous rigid structure.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to containers used for storing and/ortransporting materials. In particular, the present invention involvescollapsible containers that may be used to transport bulk materialsincluding, but not limited to, hazardous materials.

2. Discussion of Background Information

Conventional bulk containers are used for receiving, storing,transporting, and discharging all types of flowable materials; bothnon-hazardous and hazardous. Typical bulk containers include bulk bagsor rigid box structures, such as metal containers. The bag typecontainers tend to be lightweight and easily collapsible when they areempty and can transform into small volumes for easy storage andshipping. However, it is difficult to load and unload a bulk bag becauseit lacks rigidity and thus it cannot support itself in an openorientation during loading. In other words, bulk bags are generally nottough or sturdy enough to withstand the rigorous movements of mechanicaldevices such as forklifts, accidental drops into cargo holds, orstacking. On the other hand, the rigid box structures or metalcontainers have the necessary rigidity to facilitate loading, to permitstacking of loaded containers, and to allow easy handling with forkliftsand other mechanical devices. However, while the storage volume of metalcontainers is considerable, the volume of storable material withinmultiple containers is diminished by the fact that the metal containersare generally cylindrical in shape. Cylinders generally cannot be storedin a space-efficient manner. In addition, metal containers are expensiveto rent or purchase. As such, there is a need for containers that willstore a high volume of materials while being storable in a low volumestorage facility.

In order to overcome the limitations associated with flexible bags andrigid box structures or metal containers, a collapsible containerassembly has been developed. John H. Lapoint III (hereafter “Lapoint”)of Kennebunk, Me., the inventor of the present invention, developed theknown collapsible container assembly. The Lapoint collapsible storagecontainer is described in U.S. Pat. No. 6,520,403 issued Feb. 18, 2003,U.S. Pat. No. 6,000,604, issued Dec. 14, 1999, and in U.S. Pat. No.5,323,922 issued Jun. 28, 1994. The contents of the above-mentionedpatents are incorporated herein for reference.

The collapsible container developed by Lapoint is based upon amulti-walled box as shown in FIG. 1. In this configuration, container 1includes a base 3 and coupled walls 2, 4, 6, and 8, such that the wallsare made of a rigid member. Each wall is formed as a sandwich of toughwoven flexible material encasing the rigid member, e.g., a corrugatedboard. The two outer woven flexible materials are coupled together toretain the rigid member between them. Opposing walls, 2 and 8 eachinclude integral flaps 9 a and 9 b respectively, which are made from aflexible material and preferably omit the need for the rigid member.Wall 6 includes a short flap 5 and wall 4 includes integral coveringflap 11. As indicated in U.S. Pat. No. 6,520,403, flap 11 is designed toprovide a single complete covering that ensures that the material incontainer 1 will not escape under expected transport conditions. Liner13 is designed to retain a volume of material (including liquid), atleast as great as the volume of the cavity of the container 1 andpreferably to extend beyond the upper dimensions of the wall sections 2,4, 6 and 8. Liner 13 includes an opening 13 a for receiving bulkmaterial 15.

Walls 2, 4, 6, and 8 of container 1 are coupled together and arranged sothat they can be collapsed adjacent to one another while remainingcoupled together in a substantially flat configuration when nothing isretained within container 1. One advantage of the Lapoint bulk containerover the metal container is that it is stored easily and occupies muchless space compared to the metal containers. In addition, the Lapointbulk containers are substantially less expensive than the conventionalmetal containers, since they weigh less and are able to store morematerial.

However, while the Lapoint bulk container described above is animprovement over conventional bulk containers, there are many ways thatit may be improved. First, the Lapoint bulk container's collapsibilitycould be improved in such a way that it would reduce the overall foldeddimensions. Secondly, the Lapoint bulk container could be improved byutilizing existing elements to form a bottom for the bulk container.Thirdly, the Lapoint bulk container could be improved by incorporating acover that would protect the contained materials against the elements.Fourthly, the Lapoint bulk container could be improved by strengtheningthe region of the collapsible portions of the container with a device.

SUMMARY OF THE PRESENT INVENTION

The present invention is directed to a container comprising acollapsible continuous rigid structure defining a plurality of outersurfaces and a plurality of inner surfaces. Further, a liner uniformlyaffixed to at least one inner surface of the plurality of innersurfaces, such that the liner defines a sealable cavity within whichmaterial can be contained. Further still, at least one stay member isaffixed to at least one outer surface of the plurality of outer surfacessuch that at least a portion of the at least one stay member ispositioned approximate a corner formed by two adjacent outer surfaces soas to provide support to the rigid structure. A continuous or singlecover is affixed to at least one of the plurality of outer surfaces andto the at least one stay member. Further, at least one inelastic memberis connecting at least two inner surfaces of the plurality of innersurfaces and/or at least two outer surfaces of the plurality of outersurfaces so as to provide support for the continuous rigid structure.

According to an aspect of the invention,

According to an aspect of the invention,

Other exemplary embodiments and advantages of the present invention maybe ascertained by reviewing the present disclosure and the accompanyingdrawing.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is further described in the detailed descriptionwhich follows, in reference to the noted plurality of drawings by way ofnon-limiting examples of exemplary embodiments of the present invention,in which like reference numerals represent similar parts throughout theseveral views of the drawings, and wherein:

FIG. 1 is a perspective view of the collapsible container as disclosedin the PRIOR ART in U.S. Pat. No. 6,520,403.

FIG. 2 is an elevated perspective view of the collapsible containeraccording to the present invention that includes at least one verticalsupport or stay member.

FIG. 3 is an exploded perspective view of the collapsible containeraccording to the present invention that includes multiple verticalsupports or stay members.

FIG. 4 is a partial cut-away elevated perspective view of thecollapsible container according to the present invention, such that aportion of which is magnified for descriptive purposes relating to thevertical support or stay member.

FIG. 5 is an elevated perspective view of a sealed collapsible containerin accordance with the present invention that includes a top cover.

FIGS. 6, 7 and 8 are a series of partial plan views of the presentinvention illustrating the mechanism by which the container iscollapsed.

FIG. 9 is an elevated perspective view of the collapsible containeraccording to the present invention that shows multiple vertical supportsor stays members and multiple support members or patches.

FIG. 10 is a plan view of the collapsible container according to thepresent invention as shown in FIG. 9 that shows multiple verticalsupports or stay members and multiple support members or patches.

FIG. 11 is a plan view of the collapsible container according to thepresent invention that shows multiple vertical supports or stay members.

FIGS. 12 is a plan view of the collapsible container according to thepresent invention that shows multiple vertical supports or stay membersand multiple support members or patches in a half open position.

FIGS. 13 is a plan view of the collapsible container according to thepresent invention that shows multiple vertical supports or stay membersand multiple support members or patches in an open position.

FIG. 3 is an exploded perspective view of the collapsible containeraccording to the present invention that includes multiple verticalsupports or stay members.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The particulars shown herein are by way of example and for purposes ofillustrative discussion of the embodiments of the present invention onlyand are presented in the cause of providing what is believed to be themost useful and readily understood description of the principles andconceptual aspects of the present invention. In this regard, no attemptis made to show structural details of the present invention in moredetail than is necessary for the fundamental understanding of thepresent invention, the description taken with the drawings makingapparent to those skilled in the art how the several forms of thepresent invention may be embodied in practice.

FIG. 1 shows a container 1, as mentioned above relating to U.S. Pat. No.6,520,403 having a base 3 and coupled walls 2, 4, 6 and 8, such that thewalls are made of a rigid member. Each wall is formed of a sandwich oftough woven flexible material encasing the rigid member, e.g., acorrugated board. The two outer woven materials are coupled together toretain the rigid member there-between. A liner 13 is designed to retaina volume of material, e.g., including liquid, at least as great as thevolume of the cavity of the container 1. The liner 13 further includesan opening 13 a for receiving the bulk material 15. The walls 2, 4, 6and 8 of container 1 are coupled together and arranged so that they canbe collapsed adjacent to one another while remaining coupled together ina substantially flat configuration when nothing is retained within thecontainer 1.

The container represented as prior art in FIG. 1 has the disadvantage ofa collapsible container that could be structured differently so as toreduce the overall folded dimensions of the container. Further, thecontainer could be improved by utilizing existing elements to form abottom of the bulk container. Further still, the container could beimproved by incorporating a cover that protects the contained materialsagainst the elements.

The above-mentioned improvements over the prior art are addressed byJohn H. Lapoint III of Kennebunk, Me., the inventor of the presentinvention in U.S. Published patent application Ser. No. 11/054,532,(hereafter '532) filed Feb. 9, 2005 and published Aug. 10, 2006. Thecontent of the above-mentioned U.S. Published patent application Ser.No. '532 is incorporated herein by reference.

The collapsible container represented as prior art in FIG. 1 has furtherdisadvantages such that the approximate region of the collapsibleportions of the container could be strengthen to prevent potentialdeforming of the container while container is being filled or evenduring storing of the materials in the container.

The above-mentioned improvements over the prior art are addressed byJohn H. Lapoint III of Kennebunk, Me., the inventor of the presentinvention in pending U.S. patent application Ser. No. 11/333,879,(hereafter '879) filed Jan. 18, 2006. The content of the above-mentionedU.S. pending patent application Ser. No. '879 is incorporated herein byreference.

The present invention shown in FIG. 2, discloses an elevated perspectiveview of the collapsible container 10 of the present invention having atleast one vertical support or stay member rigid enough for stacking,storing and transporting a variety of materials. Unlike the metalcontainers, however, the container of the present invention can becollapsed from a substantially cubic volume into a substantially flatsquare for easy stacking and storage. The present invention thusprovides numerous benefits to the user, as described more fully belowwith reference to the drawings.

FIG. 2 is an elevated perspective view of the collapsible container 10of the present invention. The container 10 preferably includes foursides 12, 14, 16, 18 that are arranged in a symmetrical fashion so as toform part of a cubic structure defining a cavity 31 within whichmaterials may be contained. The four sides 12, 14,16, 18 are preferablyintegral portions of a continuous rigid structure. That is, the foursides 12, 14, 16, 18 are not structurally independent, and thereforeprovide a greater degree of rigidity and structural integrity than thecurrent state of the art containers. The four sides 12, 14, 16, 18preferably form a rigid structure composed of corrugated board, e.g.,fiber board or similar materials that may be readily manufactured whileproviding light weight, rigidity and ease of storage.

Still referring to FIG. 2, the container 10 of the present invention issubstantially more rigid than existing containers due to at least onevertical support or stay member 60 affixed to at least one outer surfaceof the continuous rigid structure 40 (not shown) such that at least aportion of the at least one vertical support or stay member 60 ispositioned approximate a corner 61 formed by two adjacent outer surfacesof the continuous rigid structure 40 so as to provide structuralsupport. In a preferred embodiment vertical supports or stay members 60are positioned approximate all four corners 61 of the container 10. Thevertical supports or stay members 60 can extend the entire length of thecontinuous rigid structure 40, but may be shorter. Further, thecontinuous or single cover 20 is affixed to at least one of theplurality of outer surfaces of the continuous rigid structure 40 (notshown) and to the at least one vertical support or stay member 60. It isalso possible for lifting handles 70 (not shown) to be attached to thecontinuous or single cover 20 along with being attached to the verticalsupport or stay member 60 (See FIG. 14). The aspects of the verticalsupport or stay member 60 will be further discussed in a moment see thediscussion of FIG. 4.

Although the container 10 of the present invention in FIG. 2 issubstantially more rigid than existing containers, it is also readilycollapsible and storable by a user. Two of the four sides 12, 14, 16, 18include scoring lines 42 (depicted in phantom) that permit the foursides 12, 14, 16, 18 to be collapsed into a substantially planarstructure as further described herein. The scoring lines 42 allow a userto collapse and store the present invention in the minimum amount ofspace while maintaining the structural rigidity of the container 10.

FIG. 2 further discloses cover 20 as a substantially cubic form disposedover the four sides 12, 14, 16, 18. The cover 20 defines a bottom (notshown), as well as optional flaps 22, 24 that, in use, cooperate toenclose the contents of the container 10. The cover 20 also includes aplurality of tabs 21 that may be fixed to the interior of the four sidesor inner surfaces 12 b, 14 b, 16 b, 18 b (not shown) for securing thecover 20 to the four sides 12, 14, 16, 18. The plurality of tabs 21 maybe affixed thereto by glue, epoxy, resin or any other adhesive that isknown in the art.

Optionally, the present invention in FIG. 2 shows flaps 22, 24 having atleast one end portion 26 for selectively engaging the cover 20 of thecontainer 10, thereby securing its contents. Any conventional and securefastening means may be used to secure an end portion 26 of a flap 22, 24to a corresponding portion of the cover 20. For example, the endportions 26 may include a plurality of eyelets 28 which are adapted forreceiving a plurality of ties 34, 36, 38 disposed on the exterior of thecover 20. The user may encapsulate the container 10 by folding flaps 22,24 down over the cavity of the container 10 and affixing the endportions 26 to the plurality of ties 34, 36, 38 through the eyelets 28.As the cover 20 is preferably composed of a water resistant orwaterproof material, the user can substantially insulate the container10 against all kinds of moisture and corrosive elements by closing theflaps 22, 24 in the manner described above.

Alternatively, the cover 20 could exclude flaps 22, 24 such that adetachable top (not shown) can be placed over the top portion of thecontainer and fasten to the eyelet-tie mechanism. It should beunderstood that the eyelet-tie mechanism is only one means by which thecontainer 10 may be closed, and other similar mechanisms for selectivelyaffixing two objects are equivalent to those described herein.

Still referring to FIG. 2, the four sides 12, 14, 16, 18 are sandwichedbetween the cover 20 and a liner 30 is affixed to the four sides 12, 14,16, 18 on the interior portion of the container 10. The liner 30preferably includes a fifth surface (not shown) that forms the bottomportion of the container 10. The liner 30 is preferably form-fitted tothe four sides 12, 14, 16, 18 and uniformly affixed thereto by glue,epoxy, resin or any other adhesive that is known in the art. The liner30 is affixed to the four sides 12, 14, 16, 18 in such a manner so as torender it coplanar with each of the four sides 12, 14, 16, 18. That is,the liner 30 is affixed to substantially all of the interior surfaces ofthe respective four sides 12, 14, 16, 18. As the liner 30 also includesthe bottom portion, the liner 30 and four sides 12,14, 16, 18substantially form five sides of a substantially symmetric cubicstructure. The liner 30 is preferably composed of a water resistant orwater proof synthetic material that is also resistive to degradation bytemperature and corrosive compounds.

FIG. 3 is an exploded perspective view of the container 10 of thepresent invention. As shown, the continuous rigid structure 40 is shownhaving scoring lines 42 disposed thereon. As previously noted, thecontinuous rigid structure 40 is preferably comprised of corrugatedboard, although other equivalent structures that provide the necessaryrigidity, weight, and ease of use may also be used. The liner 30 issubstantially similar in size and shape to the continuous rigidstructure 40, except for its fifth side (not shown) that forms thebottom of the container 10. The liner 30 optionally includes a foldingportion 32 (shown in cross-hatch) that is folded over the top of thecontinuous rigid structure 40 and vertical support or stay member 60,then affixed to the exterior thereof by glue, epoxy, resin or any othersuitable adhesive material or method. In one embodiment of the container10, the liner 30 may be gathered and sealed by any conventional meansfor containing the contents of the container 10. In a preferredembodiment, the liner 30 is uniformly affixed to the interior of thecontinuous rigid structure 40 so as to integrate the surfaces of theliner 30 with the inner surfaces of the continuous rigid structure 40.The resultant structure is referred to as an integrated rigid structure50. Incorporated with the integrated rigid structure is the verticalsupport or stay member 60 that is affixed to the outer surface of thecontinuous rigid structure 40 and then covered by cover 20.

Still referring to FIG. 3, the vertical support or stay member 60 isaffixed to the outer surface of the continuous rigid structure 40 bymethods known in the art such as by bonding, gluing and stapling. Cover20 can then be laminated over the vertical support or stay member 60along with the continuous rigid structure so as to form an even morestructurally support container.

FIG. 3 shows the continuous rigid structure 40 with the vertical support60 and liner 30, formed into the integrated rigid structure 50. Forexample, the liner 30 can be bonded, laminated and/or glued to the innersurfaces of the continuous rigid structure 40, and then the verticalsupport 60 can be affixed approximate the corners 61 of the continuousrigid structure 40. Finally, the cover 20 may be laminated, bondedand/or glued to both the vertical support 60 and the continuous rigidstructure 40 to formulate the integrated rigid structure 50. Theplurality of flaps 21 can then be folded over the integrated rigidstructure 50 and affixed to the interior thereof. That is, the flaps 21are affixed to the liner 30, which has been previously affixed to thecontinuous rigid structure 40, so as to prevent any exposure of thecontinuous rigid structure 40 to the elements or the materials stored inthe container 10.

The interplay between the cover 20, liner 30 and continuous rigidstructure 40 with the vertical support or stay member 60 can be seen inFIG. 4, which is a partial cut-away elevated perspective view of thecollapsible container of the present invention, a portion of which ismagnified for descriptive purposes. The magnified portion M depicts thetop edge of the container 10 where the continuous rigid structure 40with the vertical support or stay member 60 forms the core of a seriesof overlapping materials. As shown, the liner 30 is disposed on one sideof the continuous rigid structure 40, and the cover 20 is disposed onits opposite side. The foldable portion 32 is folded over the continuousrigid structure 40 and vertical support or stay member 60, then disposedunderneath the cover 20. While the tab 21 is folded over the continuousrigid structure 40, vertical support or stay member 60 and the foldableportion 32 and affixed to the interior of the liner 30. As showntherefore, both the tab 21 and the foldable portion 32 protect the topof the continuous rigid structure 40 and vertical support or stay member60 from any elemental interference. Also shown in FIG. 4 is the bottomportion of the liner 30 that comprised the bottom portion of thecontainer 10. Further, It is also possible for lifting handles 70 (notshown) to be attached to the continuous or single cover 20 along withbeing attached to the vertical support or stay member 60 (See FIG. 14).

FIG. 5 is an elevated perspective view of a sealed collapsible container10 in accordance with the present invention. As shown, a top cover 32 ispositioned on top of the container 10 and aligned with the plurality ofties 34, 36, 38. The plurality of ties 34, 36, 38 may be looped throughthe eyelets 35 on the end portions of top cover 32 in order to securethe top cover 32 and seal the container 10. It should be noted thateither arrangement, using flaps 22, 24 or top cover 32, the container 10is sealable against the elements, and in particular, the containedmaterials are shielded from moisture and debris. Further, It is alsopossible for lifting handles 70 to be attached to the continuous orsingle cover 20 along with being attached to the vertical support orstay member 60 (not shown). The lifting handles 70 may be attached bymeans of sewing, gluing and stapling. FIG. 5 shows the scoring lines 42which allow a user to collapse and store the present invention in theminimum amount of space while maintaining the structural rigidity of thecontainer 10.

FIGS. 6, 7 and 8 are a series of partial plan views of the presentinvention illustrating the mechanism by which the container iscollapsed. Unlike existing semi-rigid containers, the container of thepresent invention 10 is collapsible into a small area for easy storageand transport.

FIG. 6 is a partial plan view of the container 10 of the presentinvention omitting the cover 20 and vertical support or stay member 60.As shown, the surface of the bottom of the container 10 is the liner 30.Scoring lines 42 are shown disposed on opposing sides of the continuousrigid structure 40. It should be noted that the scoring lines 42 aresymmetrically placed about the continuous rigid structure 40 such thatthe container 10 is collapsible into a small space, through theintroduction of an accordion-fold, without stretching the liner 30 andcover 20 (not shown) which comprise the bottom of the container 10. Thescoring lines 42 are disposed on the continuous rigid structure 40 suchthat it is readily collapsible as described. However, the scoring lines42 are not sufficiently deep so as to damage or diminish the structuralintegrity of the present invention.

FIG. 7 is a partial plan view of the container 10 of the presentinvention shown at a midpoint during its collapse including the verticalsupports or stay members 60. FIG. 8 a partial plan view of the container10 of the present invention in its collapsed state wherein it forms asubstantially planar object that is substantially square and easilystored and transported.

According to another embodiment of the present invention, FIG. 9discloses an elevated perspective view of the collapsible container 10of the invention. The container 10 preferably includes a first side 12,a second side 14, a third side 16 and a fourth side 18, all of whichcooperate to define a substantially cubic volume therein. The pluralityof sides 12, 14, 16, 18 preferably delineate a continuous rigidstructure 40 that is formed from a semi-rigid material such as plastic,fiberboard or cardboard. In a preferred embodiment, the continuous rigidstructure 40 is formed of cardboard such that it can be easily andeconomically produced while providing a substantial amount of rigidityas a containment device.

Still referring to FIG. 9, the continuous rigid structure 40 includes apair of scoring lines 42 that are preferably disposed on opposing sides.For example, the scoring lines 42 may be disposed on the first side 12and third side 16, or alternatively on the second side 14 and the fourthside 18. The scoring lines 42 are preferably disposed along the centerof the respective sides thereby ensuring uniform and symmetrical foldingattributes as described more fully below. That is, a scoring linedisposed on the first side 12 will be disposed equidistant between thejunction of the first side 12 and the second side 14 and the junctionbetween the first side 12 and the fourth side 18, as illustrated in FIG.9.

FIG. 9 shows the container 10 substantially more rigid than existingcontainers due to at least one vertical support or stay member 60affixed to at least one outer surface of the continuous rigid structure40, such that at least a portion of the at least one vertical support orstay member 60 is positioned approximate a corner 61 formed by twoadjacent outer surfaces of the continuous rigid structure 40 so as toprovide structural support. In a preferred embodiment vertical supportsor stay members 60 are positioned approximate all four corners 61 of thecontainer 10. The vertical supports or stay members 60 can extend theentire length of the continuous rigid structure 40, or alternatively maybe shorter then the entire length of the continuous rigid structure 40.Further, the continuous or single cover 20 (not shown) can be affixed toat least one of the plurality of outer surfaces of the continuous rigidstructure 40 and to the at least one vertical support or stay member 60.Further still, the vertical support or stay member 60 can be affixed tothe outer surface of the continuous rigid structure 40 by methods knownin the art such as by bonding, gluing and stapling. Cover 20 (not shown)can be laminated over the vertical support or stay member 60 along withthe continuous rigid structure 40 so as to form an even morestructurally support container.

Still referring to FIG. 9, the continuous rigid structure 40 comprises asemi-rigid material as noted above, the collapsible container 10 of thepresent invention includes at least one inelastic member 48 thatinterconnects each respective side of the continuous rigid structure 40.As shown in FIG. 9, there are two inelastic members 48 that areinterwoven between the four sides of the continuous rigid structure 40in a symmetrical fashion so as to define a network of internal trussesbetween each of the four sides 12, 14, 16 and 18. In a preferredembodiment, each of the inelastic members 48 shown is formed from asingle element that can be connected to itself at an overlap 49. Theinelastic members 48 are shown anchored to each of the four sides 12,14, 16 and 18 of the continuous rigid structure 40 by passing through aseries of passages 44 that connect an inner surface of each of the foursides to an opposing outer surface. In such a manner, the internal trusssystem defined by the inelastic members 48 is integrated into thecontinuous rigid structure 40 thus forming the collapsible container 10.Further, the preferred embodiment includes support members or patches 51that are substantially fixed in and around the surrounding surface areaof the passages 44 on the continuous rigid structure 40. One of thebenefits gaining in having the support members or patches 51 fixed tothe surrounding surface area of the passages 44 is an added structuralsupport to the container 10. Some other advantages of adding theinternal truss system with a support-backing patch to the outercontinuous fiberboard, is that the truss restricts the scored sidewallsfrom protruding over the edge of a pallet, squares up the container ontothe pallet, resulting in superior stacking capability. A second criticalfunction the truss system can provide is during the transportation ofmaterials within the container. The handling and vibration duringtransport can disfigure the container if the truss system is notinstalled in the container, such that the container would most likelynot be safe to stack. Further, the truss system can restrict bulge andmaintains a square-like shape to the container during all phases ofhandling the container. Further still, the interaction between thescored sidewalls and the truss system promotes and enhances thedischarging process during the emptying phase of the container. Theforce and shear velocity due under gravity from the force of movementfrom the material can be enough force to cause the scored sidewalls toproject outwards, if the truss system were not present. Thus, resultingin an incomplete discharge of the material from the container. In mostcases, this could cause potential problems for the customer. Further,the truss forces from the two scored sides can travel towards each otherin an inwardly fashion creating a cone like funnel shape bottomproviding the slope and angel necessary for complete discharge. Thepatch supports can be made from fabric or any rigid substrate, which canhelp prevent the straps from possibly cutting the board as well as keepthe sidewalls in tack until the container is completely emptied. Theinclusion of corner vertical wood or composite stays in each cornerbonded by glue or staples can achieve a current unit stacking strengthfrom about 7900 lbs to over 15,000 lbs. By permanently affixing thestays to the outside of the fiberboard or rigid substrate on two scoredsides can not only enhance the ability of stacking. Further, when thecontainer is collapsed, the score sides can have enough clearance toaccommodate any added depth to the sidewall due to the patch and/orstays. Further still, it is possible the support members or patches 51can be selected from at least one material or a combination of materialsfrom a group consisting of polypropylene, polyester, nylon,polypropylene blend, thermoplastic polymer, polyethylene, wovenpolypropylene, high density polyethylene, low density polyethylene.

FIG. 10 is a plan view of the collapsible container of the presentinvention as shown in FIG. 9. The inelastic member 48 forms asubstantially octagonal profile by alternating periods on the inside ofthe continuous rigid structure 40 with periods on the outer surfaces ofthe respective sides. The inelastic member 48 is shown disposed on theouter surface of the fourth side 18. Following the arrows in FIG. 10,the inelastic member 48 is then pressed through a pair of passages 44 onthe fourth side 18, through which the inelastic member 48 is shownangling towards both the first side 12 and the third side 16. At thefirst side 12 and the third side 16, the inelastic member 48 is pressedthrough a pair of passages 44, from which it angles towards the secondside 14. Through another pair of passages 44 on the second side 14, theinelastic member 30 meets and is fastened to itself at the overlap 49.

In a preferred embodiment, the inelastic member 48 is of a lengthsuitable for providing a tension between the four sides of thecontinuous rigid structure 40 such that the continuous rigid structure40 maintains a substantially square shaped profile as shown in FIG. 10.Of particular concern is that the scoring lines 42 disposed on opposingsides of the continuous rigid structure 40 must be able to withstand asubstantial load as the collapsible container 10 of the presentinvention is filled. As such, the inelastic member 48 is preferablycomposed of a material that is light, inelastic and easy to deform intothe necessary profile for creating the internal truss system for thecollapsible container 10. In preferred embodiments, the inelastic member48 is polypropylene or polyester, although any other suitable synthetic,organic or inorganic polymer that can maintain its inelasticity under aload is suitable for use in the present invention. As discussed above,the support members or patches 51 are substantially fixed to thesurrounding surface area of the passages 44 of the continuous rigidstructure 40. Further, one of the benefits gained in having the supportmembers or patches 51 fixed to the surrounding surface area of thepassages 44 is an added structural support to the container 10. Furtherstill, as noted above, vertical supports or stay members 60 arepositioned approximate all four corners 61 of the container 10.

FIG. 11 is a plan view of the collapsible container 10 of the presentinvention in an early step in a method of making the same. As shown, thecollapsible container 10 is in a collapsed state in which it forms asubstantially planar cross-section. By folding in along the scoringlines 42, a user can compress the continuous rigid structure 40 in anaccordion-like manner for easy storage and transport when not in use.Note, FIG. 11 shows the support members or patches 51 substantiallyfixed to the surrounding surface area of the passages 44 of thecontinuous rigid structure 40. Further, as noted above, verticalsupports or stay members 60 are positioned approximate all four corners61 of the container 10.

In order to form the internal truss system described above (see FIG.11), the planar continuous rigid structure 40 is perforated to form theplurality of passages 44, which pass continuously and symmetricallythrough each of the four sides of the continuous rigid structure 40. Ina preferred embodiment, the plurality of passages 44 are formed by apressing machine adapted to thread the inelastic member 40 through thepassages 44 as it creates them. Alternatively, the process of formingthe plurality of passages 44 and the placement of the inelastic member48 therein may be performed manually. As discussed further below, it isalso conceived that the continuous rigid structure 40 of the presentinvention can be lined on its interior surfaces, in which case it isdesirable to fit the liner into the continuous rigid structure 40 priorto threading the inelastic members 48 through the plurality of passages.Note, the support members or patches 51 substantially fixed to thesurrounding surface area of the passages 44 of the continuous rigidstructure 40.

FIGS. 12 is a plan view of the collapsible container according to thepresent invention that shows multiple vertical supports or stay membersand multiple support members or patches in a half open position. Theinelastic member 48 is shown fastened to itself at the overlap 49. Themeans for fastening the inelastic member 48 to itself may includemechanical devices, adhesives and other bonding techniques. For example,the inelastic member 48 may be fasted to itself using staples, epoxiesor resins. Preferably, however, the means for fastening will be anautomated process such as sonic welding, which is particularly wellsuited to bonding materials composed of synthetic polymers such aspolypropylene and polyester. As shown in FIG. 12, the overlap 49 of theinelastic member 48 is located near the outer surface of the second side14. While it is understood that the overlap 49 can be located at anypoint along the continuum of the inelastic member 48, it is preferredthat it be located near the outer surface of a side of the continuousrigid structure 40 that does not have a scoring line 42.

FIGS. 13 is a plan view of the collapsible container according to thepresent invention that shows multiple vertical supports or stay membersand multiple support members or patches in an open position. As notedbefore, the inelastic member 48 is preferably of a single length ofmaterial that, when stretched to its limit, will maintain thesubstantially square profile of the continuous rigid structure 40. Inparticular, when a load is placed upon the inner surfaces of thecontinuous rigid structure 40, the sides of the continuous rigidstructure 40 that have the scoring lines 42 therein will not bow ordeform in an outward direction. However, as previously noted, theinelastic member 48 will permit the inward folding of the continuousrigid structure along the scoring lines 42, thus allowing a user tocollapse the continuous rigid structure 40 into a substantially planarform as shown in FIG. 11. Further, FIG. 13 shows the support members orpatches 51 substantially fixed to the surrounding surface area of thepassages 44 of the continuous rigid structure 40. Further still, thevertical supports or stay members 60 are positioned approximate all fourcorners 61 of the container 10.

According to another embodiment of the present invention, FIG. 14 showsan exploded perspective view of the container 10. As shown, thecontinuous rigid structure 40 is shown having scoring lines 42 disposedthereon. As previously noted, the continuous rigid structure 40 ispreferably comprised of corrugated board, although other equivalentstructures that provide the necessary rigidity, weight, and ease of usemay also be used. The liner 30 is substantially similar in size andshape to the continuous rigid structure 40, except for its fifth side(not shown) that forms the bottom of the container 10. The liner 30optionally includes a funnel section 63 having a detachable threadedspin cover 61 with opening 62, which is then affixed to the foldingportion 32. In one embodiment of the container 10, the liner 30 may begathered and sealed by any conventional means for containing thecontents of the container 10. In a preferred embodiment, the liner 30 isuniformly affixed to the interior of the continuous rigid structure 40so as to integrate the surfaces of the liner 30 with the inner surfacesof the continuous rigid structure 40. Further, a second liner 30 a issubstantially similar in size and shape to the continuous rigidstructure 40, except for its fifth side (not shown) that forms thebottom of the container 10. The second liner 30 a optionally includes asecond funnel section 63 a with second opening 62 a, which is thenaffixed to the second folding portion 32 a. In one embodiment of thecontainer 10, the second liner 30 may be gathered and sealed by anyconventional means for containing the contents of the container 10. In apreferred embodiment, the second liner 30 a is uniformly affixed to theexterior of the continuous rigid structure 40 so as to integrate thesurfaces of the second liner 30 a with the exterior surfaces of thecontinuous rigid structure 40. An advantage incorporating the secondliner 30 a is to hermetically seal the material within the container 10.Then, a second continuous rigid structure 40 a is shown having scoringlines 42 a disposed thereon. The second continuous rigid structure 40 ais preferably comprised of corrugated board, although other equivalentstructures that provide the necessary rigidity, weight, and ease of usemay also be used. The second liner 30 a is substantially similar in sizeand shape to the continuous rigid structure 40 a, except for its fifthside (not shown) that forms the bottom of the container 10. Finally, acontinuous or single cover 200 is affixed to at least one of theplurality of outer surfaces of the second continuous rigid structure 40a and to the at least one vertical support or stay member 60 a. It isalso possible that lifting handles 70 can be attached to the continuousor single cover 200 along with being attached to the vertical support orstay member 60 a. The continuous or single cover 200 can be selectedfrom a foil material, a foil-like material or a pyroforic material orany combination thereof. Further, it is possible the foil material maybe laminated to the polypropylene so as to provide some temperature andultra-violet protection.

Still referring to FIG. 14, the vertical support or stay member 60 a canbe affixed to the outer surface of the continuous rigid structure 40 aby methods known in the art such as by bonding, gluing and stapling.Cover 200 can then be laminated over the vertical support or stay member60 a along with the second continuous rigid structure 40 a so as to forman even more structurally support container.

The container 10 of the present invention as described herein provides anumber of tangible benefits over the existing rigid and semi-rigidcontainers known in the art. The container of the present invention isrigid enough for stacking, storing and transporting a variety ofmaterials that other semi-rigid containers cannot handle. Moreover,unlike the rigid metal containers, the container of the presentinvention can be collapsed from a substantially cubic volume into asubstantially flat square for easy stacking and storage.

It is noted that the foregoing examples have been provided merely forthe purpose of explanation and are in no way to be construed as limitingof the present invention. While the present invention has been describedwith reference to an exemplary embodiment, it is understood that thewords which have been used herein are words of description andillustration, rather than words of limitation. Changes may be made,within the purview of the appended claims, as presently stated and asamended, without departing from the scope and spirit of the presentinvention in its aspects. Although the present invention has beendescribed herein with reference to particular means, materials andembodiments, the present invention is not intended to be limited to theparticulars disclosed herein; rather, the present invention extends toall functionally equivalent structures, methods and uses, such as arewithin the scope of the appended claims.

1. A container comprising: a collapsible continuous rigid structuredefining a plurality of outer surfaces and a plurality of innersurfaces; a liner uniformly affixed to at least one of the plurality ofinner surfaces, wherein the liner defines a sealable cavity within whichmaterial can be contained; at least one stay member affixed to at leastone outer surface of the plurality of outer surfaces such that at leasta portion of the at least one stay member is positioned approximate acorner formed by two adjacent outer surfaces so as to provide support tothe rigid structure; a continuous or single cover affixed to at leastone of the plurality of outer surfaces and to the at least one staymember.
 2. The container of claim 1, wherein at least one inelasticmember connects at least two inner surfaces of the plurality of innersurfaces and at least two outer surfaces of the plurality of outersurfaces so as to provide support for the continuous rigid structure. 3.The container of claim 1, wherein the at least one stay member isaffixed to each of the plurality of outer surfaces such that each staymember is substantially positioned along each corner formed by twoadjacent outer surfaces.
 4. The container of claim 1, wherein the atleast one stay member is affixed to the at least one outer surface ofthe plurality of outer surfaces by one of bonding, laminating, glue andstapling.
 5. The container of claim 1, wherein, the at least one staymember is laminated in a composite material prior to being affixed tothe at least one outer surface of the plurality of outer surfaces. 6.The container of claim 1, wherein the at least one stay member is madeof at least one material or a combination of materials from a groupconsisting of wood and composite.
 7. The container of claim 1, whereinthe at least one stay member is one of a unitary element and more thanone element.
 8. The container of claim 1, further comprising at leastone inelastic member connecting at least two inner surfaces of theplurality of inner surfaces and at least two outer surfaces of theplurality of outer surfaces so as to provide support for the continuousrigid structure.
 9. The container of claim 1, wherein the continuousrigid structure includes a first scoring line and a second scoring linerendering the continuous rigid structure collapsible.
 10. The containerof claim 8, wherein the first scoring line and the second scoring lineare on opposing surfaces of the continuous rigid structure.
 11. Thecontainer of claim 1, wherein the liner is uniformly affixed to each ofthe plurality of inner surfaces.
 12. The container of claim 1, whereinthe liner is an impervious liner adapted to withstand temperatures ofmaterial in excess of 300° F.
 13. The container of claim 11, wherein theimpervious liner comprises of at least one material or a combination ofmaterials selected from a group consisting of polypropylene, nylon,polypropylene blend, thermoplastic polymer, polyethylene, wovenpolypropylene, high density polyethylene, low density polyethylene. 14.The container of claim 1, wherein the liner is waterproof and/orultraviolet protected.
 15. The container of claim 1, wherein thecontinuous or single cover is affixed to all the plurality of outersurfaces.
 16. The container of claim 1, wherein the continuous or singlecover is affixed to at least one of the plurality of outer surfaces andat least a portion of at least one of the plurality of inner surfaces.17. The container of claim 1, wherein the continuous or single cover isaffixed to each of the plurality of outer surfaces and at least aportion of each of the plurality of inner surfaces.
 18. The container ofclaim 10, wherein the continuous or single cover is laminated to one ofeach of the plurality of outer surfaces and at least one of theplurality of outer surfaces.
 19. The container of claim 1, wherein thecontinuous rigid structure is a unitary device adapted for beingalternately collapsed for storage and erected to a self-supportingconfiguration for receipt and containment of the material.
 20. Thecontainer of claim 1, wherein the material is one of non-hazardous andhazardous material.
 21. The container of claim 20, wherein the materialcomprises a catalytic material.
 22. The container of claim 1, whereinthe collapsible continuous rigid structure is selected from at least onematerial or a combination of materials from a group consisting ofcorrugated board, fiber board and composite material.
 23. A containercomprising: a collapsible continuous rigid structure defining aplurality of outer surfaces and a plurality of inner surfaces; a lineruniformly affixed to at least one inner surface of the plurality ofinner surfaces, wherein the liner defines a sealable cavity within whichmaterial can be contained; a continuous or single cover affixed to atleast one of the plurality of outer surfaces; at least one inelasticmember connecting at least two inner surfaces of the plurality of innersurfaces and/or at least two outer surfaces of the plurality of outersurfaces so as to provide support for the continuous rigid structure;wherein the at least one inelastic member is in contact with at leastone supporting material affixed to a portion of the at least two innersurfaces and/or the at least two outer surfaces.
 24. The container ofclaim 22, wherein the at least one inelastic member connects the atleast two inner surfaces and the at least two outer surfaces through atleast one first pair of passages positioned within each inner surface ofthe plurality of inner surfaces and/or each outer surface of theplurality of outer surfaces, thus providing support for the continuousrigid structure.
 25. The container of claim 22, wherein the at least oneinelastic member connects the plurality of inner surfaces and theplurality outer surfaces through at least one first pair of passagespositioned within each inner surface of the plurality of inner surfacesand/or each outer surface of the plurality of outer surfaces, thusproviding support for the continuous rigid structure.
 26. The containerof claim 22, wherein each of the inner surfaces of the plurality ofinner surfaces and/or each of the outer surfaces of the plurality ofouter surfaces further define at least one second pair of passages. 27.The container of claim 25, further comprising a second inelastic memberconnecting the plurality of inner surfaces and the plurality of outersurfaces, such that the second inelastic member passes through each ofthe second pair of passages within each of the inner surfaces and/or theouter surfaces.
 28. The container of claim 22, wherein the at least oneinelastic member and/or the at least one supporting material is selectedfrom at least one material or a combination of materials from a groupconsisting of polypropylene, polyester, nylon, polypropylene blend,thermoplastic polymer, polyethylene, woven polypropylene, high densitypolyethylene, low density polyethylene.
 29. The container of claim 22,wherein the at least one inelastic member is comprised of a singlelength of material that is fastened to itself to form a continuousmember.
 30. The container of claim 22, wherein at least one stay memberis affixed to at least one outer surface of the plurality of outersurfaces such that at least a portion of the at least one stay member ispositioned approximate a corner formed by two adjacent outer surfaces soas to provide support to the rigid structure.
 31. The container of claim30, wherein the at least one stay member is affixed to each of theplurality of outer surfaces such that each stay member is substantiallypositioned along each corner formed by two adjacent outer surfaces. 32.The container of claim 30, wherein the at least one stay member islaminated in a composite material prior to being affixed to the at leastone outer surface of the plurality of outer surfaces.
 33. A containercomprising: a first collapsible continuous rigid structure defining aplurality of first outer surfaces and a plurality of first innersurfaces; a first liner uniformly affixed to at least one first innersurface of the plurality of first inner surfaces, wherein the firstliner defines a sealable cavity within which material can be contained;at least one inelastic member connecting at least two first innersurfaces of the plurality of first inner surfaces and/or at least twofirst outer surfaces of the plurality of first outer surfaces so as toprovide support for the first continuous rigid structure; a second lineruniformly affixed to at least one first outer surface of the pluralityof first outer surfaces, wherein the second liner sealable encloses thefirst liner; a second collapsible continuous rigid structure defining aplurality of second outer surfaces and a plurality of second innersurfaces; a second continuous or second single cover affixed to at leastone second outer surface of the plurality of second outer surfaces. 34.The container of claim 33, wherein the at least one inelastic member isin contact with at least one supporting material affixed to a portion ofthe at least two inner surfaces and/or the at least two outer surfaces.35. The container of claim 33, wherein the first and second continuousrigid structure includes a first scoring line and a second scoring linerendering the first and the second continuous rigid structurecollapsible.